Group No: G7

Module Name: ME1071

Semester: 2

FAMILIARISATION WITH SHEET

METAL FORMING
By

Index No. Name Marks

200275A JEYARAJ J.S.P.

Group members

Index No. Name

200231L IMADUWA I.N.N.
200243B JAYAKODY J.P.C.L.
200246L JAYALATH J.W.K.N.
200268F JAYAWARDHANA N.V.
200271H JAYAWICKRAMA H.I.K.
200275A JEYARAJ J.S.P.
200278K NILMAN K.A.D.S.
200290N KARUNANAYAKA K.P.N.S.B.
200319N KUMARA M.A.S.J.
200320J KUMARA M.H.R.

Date of practical session

Date of submission

Instructor’s name

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka
 INTRODUCTION

Sheet metal forming is the process of changing thin and flat pieces of metal into useful shapes through
operations such as cutting, bending, hemming, seaming and other operations. Various set of
specialised tools and machines are used for this process and these processes are conducted in a
specialized workshop known sheet-metal shop. Vast variety of products from tin containers to
automobile body parts use this process to get the desired shapes.

Galvanised iron, black iron, tin, copper, and aluminium are commonly used metals for sheet metal
works. Marking tools, measuring instruments, holding tools, cutting tools, and striking tools are
utilised for sheet metal works.

We were guided on how to make a hexagonal tray using a galvanised iron sheet during this practical
and most of the machines and tools in the sheet metal shop were introduced to us.
 JEWELLERY BOX MANUFACTURE

TOOLS AND MACHINES USED

• Divider
• Scriber
• Metre ruler
• Wooden mallet
• Straight snip
• Sheet metal folder
• Creasing stake
• Spot welding machine

STEPS FOLLOWED

I was given a square shaped sheet of galvanised iron. First, I found the centre of this sheet by
connecting the diagonals of the square sheet. On this connecting point I placed the divider and drew a
circle of radius 50mm. On this circle I marked arcs of 50mm using the divider by alternating the
starting point to the new point marked and connected these marked points to get a hexagon using the
scriber. Then as shown in the Figure 5 the other parts were marked using the scriber.

Then using the straight snip, I cut the excess sheet very carefully as to not cut out of the marked lines.
A special precaution was taken not to press the snip fully as the further tip of snip may deform the
sheet (Figure 1).

After cutting the sheet I flattened the sheet using the flat faced wooden hammer (Figure 2). Then using
the manual sheet metal folder, I folded the outer hem of the sheet and using the same machine I
applied pressure to make the hem flat and stiff. Hemming is done to get rid of sharp edges which
could harm the users and to add strength to the structure.

After folding all 6 hems, I folded the rectangular parts marked as B in the diagram using the creasing
stake (Figure 3) so that they make 90⁰ to the hexagonal part and the folded seams face outside. After
each fold I turned the sheet to the other side of the creasing stake and using the wooden mallet made
the folding edge neater and sharper (Figure 4).

Then by placing the parts marked as C on the folded rectangular parts I spot welded them using spot
welding machine to make lap joint. After doing this for all 6 parts the jewellery box is completed.

Figure 1 Figure 2
Figure 3 Figure 4

Figure 5
 SAFETY PRECAUTIONS FOLLOWED IN SHEET METAL SHOP

No loose clothing or loose hair was allowed in the sheet metal shop since they might get entangled and
cause damage to us and machines. Further protective shoes are recommended and if they are not
available leather shoes are compulsory as heavy tools or machine component might fall on to the legs.

Eye protection is recommended as small piece of metal might be thrown away while shearing.

Metallic hammers are not generally used since they can harm the sheet and other tools should also be
used with care as not to damage the sheet metal.

Wearing gloves is advisable during snipping and handling unseamed edges as deep cut can happen due
to sharp edges.

PROCESS OF BENDING AND IMPORTANCE OF SPRING-BACK EFFECT

Sheet metal bending is the process of applying a stress to a sheet metal beyond its yield strength, so it
deforms and bends without fracture or failing. Bending can be done manually by hand in thinner
sheets, using folding or bending machines for thick sheets and there are other hand-held bending tools
too.

There are various methods of bending sheet such as V-bending, air-bending, bottoming which use v
blocks and various punches, wipe bending is the type of bending we performed during bending the
rectangular parts of the jewellery box using creasing stake and roller bending where sheet metals are
sent through pre-set set of rollers to obtain different shapes.

SPRING-BACK EFFECT

Spring-back effect is often experienced when sheet metals are attempted to bend. This is basically the
final bending angle being less than the attempted bend angle. This is due to the object attempting to
return to its original position when bending force is released due to the resistive forces acting against
the bending force internally in the material.

The common practice to compensate for the spring-back effect is to bend slightly more than desired
bend angle so that it will spring-back to the desired angle. There are special tools too for this (relieved
v die). The spring-back angle also differs from material to material.

• Cold-rolled steel: 0.75⁰

• H32 Aluminium: 2.5⁰
• 304 stainless steels: 2.75⁰

Knowing these spring-back angles and methods to calculate spring back values and techniques to
compensate to the spring back effect are very important to do the sheet metal bending efficiently.
 RECTANGULAR DUCT WITH END CONNECTIONS

TOOLS AND MACHINES USED

• Try square
• Scriber
• Metre ruler
• Wooden mallet
• Straight snip
• Sheet metal folder
• Creasing stake
• Spot welding machine

STEPS FOLLOWED

First the development should be drawn as shown in the Figure 6 using the scriber meter ruler and try
square. Then the sheet-metal should be cut using a straight snip around the marked lines. This should
be done carefully as material is not wasted due to wrong cuts.

After cutting the sheet should be flattened using the flat faced wooden hammer. Then the sections
marked as 1 should be bent 90⁰ outward such that they could be used for transverse joints. This
bending could be done using the creasing stake and wooden hammer as before. Then these bent parts
should be folded in half and flattened using the sheet metal folder. This is done for added rigidity.
Then the sections A, B, C, D should be bent along marked lines such that the angle between each
section is 90⁰. This can be achieved by wipe bending.

After all 3 edges are bent to 90⁰ the part marked as 2 should be bent such that it touches the outer
surface of section A and should be spot welded to form a lap joint. For longer distances if a suitable
spot welder is not present, a locked seam can be made.

Similar ducts made in this method can be joined by spot welding the hems or by drilling holes through
the hems and attaching with screws.

Figure 6
REFERENCES

• J. Lee, “Sheet Metal Bending: Basics, Types, and Tips for Product Designers,” Gensun Precision
Machining, Apr. 03, 2022. https://www.china-machining.com/blog/sheet-metal-
bending/#:~:text=The%20sheet%20metal%20bending%20process%20involves%20applying%20a%20f
orce%20to (accessed Sep. 19, 2022).
• “Bending Basics: The hows and whys of springback and springforward,” www.thefabricator.com.
https://www.thefabricator.com/thefabricator/article/bending/bending-basics-the-hows-and-whys-of-
springback-and-springforward (accessed Sep. 19, 2022).
• “Joining rectangular ducting,” www.ductstore.co.uk.
https://www.ductstore.co.uk/acatalog/Help_on_rectangular_ducting.html (accessed Sep. 19, 2022).